70]A few things have happened since my last post. Most of them were in preparation for attending Wuste European Car Festival in Las Vegas over June 3-4.

Switched to 91 octane from E85, ran 2 tanks (basically there and back), and switched back to E85 a few days ago. Still waiting on Motoza for my next E85 revision, though... it's been 3 weeks now... but that revision should increase boost to ~25psi.

Very curious how the new increased boost tune is performing. I'm new to audiforums ( and I own a Passat) but stumbled across this great write up and realized your setup is almost exactly the same as mine (engine wise, anyway). Was the rod install worth the time and expense with the frankenturbo and E85? I'm on the fence right now as far as rods go and am very interested in your feedback. Thanks

 

Still not yet to 25psi, I'm thinking Motoza might be slowly ramping boost up across revisions. (and I'm slow to take logs) Only at ~22psi right now, and it doesn't feel a whole lot faster but off-boost and during-spool power did seem to improve. Guessing Motoza may have increased timing or something.

Couldn't tell you if the rods were worth it, but at least from a peace of mind perspective they are. Besides, I did a LOT of other work while the engine was out, and I had to take the time off work anyways (and didn't have other things to do with that time off).

 

Hey, found your build looking for 1.8T E85 experiences. Maybe I missed it in your long thread, but do the original fuel lines and seals cope with E85 or did you need to upgrade? Thanks in advance and feel free to direct me to an earlier post with this info if this has already been covered!

 

Yeah I'm running a stock fuel system except for fuel pump and injectors. These have both only been upgraded to ensure sufficient supply of E85 since E85 requires ~35% more fuel compared to gasoline for a given power output.

 

Cheers, MetalMAN!

 

Took my A4 to the dyno on 9/30/16 as Motoza seemed pretty confident the tune is "done" after the 5th revision of the 3bar MAP sensor tune. (had probably 20 revisions on the original E85 tune)
Dyno is a Dynapack (connects to wheel hubs), and ambient air temp was about 82 degrees.

Relevant mods at time of dyno:

• 2001 A4 1.8TQM, 126k miles and stock engine (minus rods)
• FrankenTurbo F21 kit (non-mixed flow, purchased June 2014)
• Motoza tuned with switchable maps, running E85 currently
• Bosch EV14 750cc injectors, seeing ~75% max IDC. Stock 4bar FPR.
• Deatschwerks DW200 fuel pump
• engine has I.E. connecting rods, and tune accommodates them
• 3" MAF housing
• 3bar MAP sensor
• Treadstone TR18T FMIC, 2.5" cold-side and 2" hot-side piping
• 034 3" HFC
• 2.5" custom cat-back exhaust with Magnaflow mufflers
• B7 RS4 clutch kit with ECS Tuning RA4 flywheel
• the car's tune is conservative enough that it doesn't see more than 1.5 degrees of knock on any cylinder at WOT
• car hits 25psi, but tapers to prevent MAF readings from going much above 240 g/s to improve turbo life

As you see, max torque shown is 1270 ft-lbs; this is the direct reading from the wheels. To get engine torque, you divide that 1270 by the drivetrain reduction (4.108:1), and that's how 309 AWTQ is calculated.

The lesser dashed lines are from a prior dyno 2.5 years ago. That was the old FT F4H turbo, and on 91 octane, and with a clutch that I believe was slipping.

 

Wondering what 3 bar MAP sensor you used? Bosch 0281002437?
thanks

 

I used the Bosch 0281002401 3bar MAP sensor. Since the stock 2.5bar sensor has a larger diameter at the seal, this 3bar unit requires a grommet to adapt it to seal in the original 2.5bar MAP hole. Something like this:
3-Bar MAP Grommet - 05616640 - 05616640 - IDParts.com

 

Wow almost 10 months months since my last real update... haven't done a ton other than maintenance, but one cool thing I finished 10 months ago was my 3D printed defroster vent boost gauge vent with AWE gauge:



Also did the bi-annual SMOG test after parts swapping, then swapped back same-day lol.
Replaced 2 CV boots (one front one rear) that were torn.

Replaced my radiator with a Nissens brand aftermarket one. That was a mistake... in a very short time it started leaking from the drain because of a poor molded part that tore the O-ring on the drain stopcock.
Replaced with a new Genuine radiator and no more problems.

On the B6, I've mostly been driving it, and fixing things here-and-there. I have the APR Stage 3+ turbo/manifold/cat off with the whole front end torn apart, because of a failed weld on the APR cat flange:





Got that rewelded, and now just waiting on new gaskets before it all goes back together:



For the B6 I'm amassing parts to put it back to stock. Haven't made any final determination on what will happen with the APR Stage 3+ parts (turbo / manifold / cat / inlet pipe) but contemplating dropping them into my B5 since my B5 has much better supporting mods than the B6.
Then maybe drop in a GTX2860R Gen 2 to replace the GT2860RS from the APR kit... which would give improved spool, more efficiency, and more power.

Have spent a ton of time on 3D printing, including designing a new machine and building it from scratch (it has many 3D-printed parts). This took away a lot of time from car stuff!

Also I hope to fix the pictures... stupid Photobucket destroyed my thread when they decided to disable hotlinking photos unless paying them $400 per year.

 

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